Electroforming method for producing radiators



H. EwlNG ocr. 28, 194'1.

l ELECTROFORMING METHOD FOR PRODUCING'RADIATORS Filed NOX-r'.` 29, 1937 2 Sheets-Sheet 1 @om 60%@ @MWM wwwwwwowwwoo@ wwowowfww@ wwwwwwwwowwwoowwwww @owwoww Mama/u Patented Oct. 28., 1941 ,UNITEDl STATES PATENT OFFICE azsmsss ELECTROFORMING METHOD FOR PRODUC- ING RADIATORS Herbert 0. Ewing, Middleport, Ohio Application November 29, 1937, Serial No. 177,107

(c1. toi-s) 3 Claims.

This invention relates to improvement in the art of making radiators and similar hollow tubular or honey-comb structures,`and the primary object of the invention is to provide 'a novel process whereby radiators and analogous structures may be inexpensively produced, and the hollow tubular body thereof formed as an integral seamless one-piece structure of great strength, the expense and other` objections incident to soldering, brazing or other modes of the building of structure of thisl character being avoided, the seamless construction rendering the radiators free from leakage even though they may be subjected to vibration-and other stresses.

The invention involves an improved process for the manufacture of hollow cellular heat-exchange bodies, such as automobile radiators and the like, by electrolytic deposition of copper or other metal of requisite strength on a fusible metal matrix or core, which matrix is subsequently removed from the electrolytically deposited metal by melting it from the formed body.

A specific object of the invention is the provision of a novel process for producing one-piece seamless radiators or other cellular heat-exchangebodies, by, first, producing a fusible matrix or core of the desired'conguration, and, then, electrolytically depositing suitable metal thereon, and the provision of steps Ain the proeessV for controlling the thickness of the electrolytically deposited metal at any point or area in the article to be produced.

A mkore specific object of this invention is the provision of an approved process for producing radiators or other hollow heat-exchange bodies, by, iirst,forming a matrix of fusible metal having a configuration to produce the required article, electrolytically depositing a coating of metal on the core or matrix, positioning the matrix or core with the electrolytically deposited metal thereon in a bath of paraffin or other suitable material to which the electrolytically deposited metal will not adhere during the electrolysis, again positioning the corev or matrix with the electrolytically deposited metal thereon in an electrolytic bath or electrolyte to electrolytically deposit additional metal on the parts which have not been masked or coated by the palaln, and repeating this process until the desired quantity of metal is deposited on all parts of the matrix core to insure a strong body, and then melting the fusible core from the electrolytically deposited metal so that the electrolytically deposited metal forms a strong one-piece seamless cellular heatexchange body or shell.

v Another object of this invention isthe provision of a process for electrolytically producing strong one-piece seamless cellular bodies, such as radiators and the like, by providing a matrix joining component parts as usually practiced in or core to which suitable reinforcing members or vcomponents are secured, and then electrolytically depositing suitable metal, having a higher fusing point than the relatively s oft fusible core or matrix, on the core or matrix and also on the reinforcing members until a sufficient quantity of the metal is electrolytically deposited on the matrix and the reinforcing components, and then melting the fusible matrix from the electrolytically deposited metal and the reinforcing members leaving the reinforcing members secured to the electrolytically deposited metal to form reinforcements at the point of union between the reinforcing members 'and the electrolytically deposited metal.

A further object of this invention is the provision of a novel method for forming hollow or cellular bodies by electrolytically depositing suitable metal on prepared cores or matrices and circulating the electrolyte so that equal quantities of metal will be deposited at opposed sides of the matrices.

With the foregoing and other objects in View, which will appear as the description proceeds, the, invention resides in the combination and arrangement of parts,` and in the details of construction hereinafter described and claimed, it

being understood that various changes in form, proportion, or details of construction may be made within the scope of the claims without departing from the spirit or sacrificing any adwhich the electrolyte, anodes and the matrices v or cores are positioned during the electrolytic process,

Figure 3 is a vertical lsectional view taken through the mechanism for coating the matrix or core and the electrolytically deposited metal with a suitable ,coating of paraffin or other fluid to which the electrolytically deposited metal will not adhere during the electrolysis process,

Figure 4 is a vertical sectional view taken on the line 4,-4 of Figure 3,

Figure 5 is an enlarged fragmental elevational view depicting a portion o f the tube or cell forming component of the radiator core or matrix,

Figure 6 is an enlarged fragmental elevational view depicting the tubular portion o'f the formedV radiator, parts appearing in section, l

Figure 7 is an enlarged detailed sectional view taken through the core or matrix with a quantity of electrolytically deposited metal thereon and disclosing the condition of the radiator or cellular body during a phase of its formation,

Figure 8 is a similar view but depicting a portion of the matrix or core submerged to a predetermined depth in a paran or other suitable masking bath, and showing other portions of the matrix or core coated with the paraffin or masking material, f

Figure 9 is a view similar to Figure '7 but depicting the condition of the body after additional metal has been electrolytically deposited there- Figure 10 is a detailed sectional view taken through the matrix, and depicting the method of securing reinforcements to the electrolytically deposited metal, and

Figures 11 and 12 are similar views butv depicting the method of securing reinforcements of dierent configurations to the electrolytically deposited metal.

Referring to the drawings in which similar reference characters designate corresponding parts, there is depicted in Figure 1 a radiator I5 formed by my improved process or method. Although radiators or other hollow heat-exchange members of various types may be formed with my process, the radiator here depicted is typical of the type to be 4employed in connection with internal combustion engines in which water is circulated around the combustion chambers and through a radiator to cool the engine. The radiator depicted includes a hollow crown tank or receptacle 'I6 formed at its upper portion 4and a hollow settling tank or pan I1 located at its lower portion.y Cellular members or tubes I8 are formed in the body of the radiator between the tanks I6 and I 1 and the sides 28 of the radiator. The Ventilating or radiating tubes may be of any shape or form but the rectangular or diamond shape tubes I8, best depicted in Figures 1, and 6, presents a preferred configuration. An inlet nipple or tube 2| is positioned in the lower portion of the radiator to communicatewith the settling tank I1, and a similar nipple 22 communicates with the upper tank I6. There are various ways for securing the radiator I5 to its supporting structure, such as the chassis of an automobile, and to this end flanged securing ears 23 are formed adjacent the lower terminal of the radiator. Bolts or other suitable securing devices pass through the outwardlyY extending flanges 23a of the securing ears 23 to rigidly secure the radiator to its supporting structure, but inasmuch as such securing means are well understood by those skilled in the art and form no part of this invention they have not been illustrated in this application.

ing point. The matrix is cast in solid form, and

in order to form the cellular or tubular radiating portion of the radiator, angularly disposed ribs 25 and 26. best shown in Figure 5, are provided, and these ribs intersect to form diamond shape or rectangular tubes 21 which extend entirely through the matrix or radiator core, as best shown in Figures 5, 7 and 8.

Any preferred number of suitably formed matrices or radiator cores 24 are positioned preferably ,in the central portion of an elongated rectangular tank or vat 28, shown in Figure 2, and this tank is formed of suitable material for the reception of the usual electrolyte. At each side of the row of matrices or cores 24 there is provided a perforated vertically-disposed partition 30, and the perforations 3I of these partitions are arranged to aid in uniformly distributing and circulating the electrolyte in the vat or tank 28 so that each core or matrix 24 is subjected to a suiiicient quantity of electrolyte, as will be hereinafter more fully disclosed. To this end the apertures or perforations 3| ofthe partitions 30 are positioned progressively closer together as the end terminals 29 of the vat or tank 28 are approached. Although any preferred material capable of electrodepositlon may be employed to form the radiators about the cores or matrices, copper is a preferred material, and, to this end, a plurality of copper anodes 32 are positioned in the tank or vat preferably at each side of the row of matrices and inside the perforated partip tions 30. A conduit 33 communicates with the vat or tank 28 at one side of the row of radiator cores or matrices, and a similar conduit 35 communicates with the vat at the opposed side of the radiator cores. The conduits 33 and 35 communicate with a reversible circulating pump 36 of conventional construction which may be driven from any suitable source of power. A preferred means for driving the reversible circulating pump 36 includes a reversible electric motor 31 of conventional construction which is operably con- After the cores or matrices 24 have been positioned in the vat or tank 28, the reversible electric motor 31 is actuated to drive the circulating pump 36. During the operation of the pump 36, it is driven in one direction for a given period and then reversed and driven in the opposed direction for a like period, thereby circulating the electrolyte, first, in one direction and, then, in the opposed direction through the perforated partitions 30, so that copper from the anodes 32 are deposited on the fusible matrices or radiator cores whichare electrically connected in the circuit to serve as cathodes. The conduits 33 and 35 communicate with the tank or vat 28 near its central portion and at each side of the matrices, and by positioning the apertures or perforations 3I of the partitions 30 progressively closer together as the ends 29 of the vat are approached, the electrolyte is uniformly circulated so that a like quantity of electrolyte and electrolytic metal reaches each radiator core. This process is continued until the requisite quantity of metal is electrolytically deposited on the open and exposed surfaces of the fusible radiator core or matrix.

It is well known, however, to those skilled in the art, that in the action of an electrolytic process a greater quantity of metal is deposited on open exposed surfaces than on the more remote congested surfaces; having a plurality of small elongated cells or tubes, a greater quantity of metal is deposited on the front and rear walls of the radiator matrix and on the exposed peripheral surfaces of the matrix tubes than on the central portion of the matrixitubes 21. In the form of radiator here In forming a radiator depicted, the cells -or tubes 21 are of relatively small cross section and of relatively great length, consequently the intermediate portion of each tube 21 receives practically none, or, at best, a small quantity of electrolytically deposited metal. In Figure 7 there is depicted the condition of the radiator matrix after it has been subjected to the action of the electrolyte bath. 'Ihe front and rear walls of the matrix 24 are supplied with ample electrolytically deposited metal but the intermediate portion 21a of each tube 21 has, at best, a thin coating of .electrolytically deposited metal.

This, of course, produces a faulty radiator structure. because the thin intermediate portion of each tube would break down in commercial use.

, If thev electrolytic process were continued long enough to deposit the requisite quantity of metal on the intermediate portion of each cell or tube, then an excess quantity would be deposited on the open or exposed surfaces of the radiator core.

In order to overcome this difficulty and to produce a radiator having walls of controlled thickvness throughout, applicant provides a tank or receptacle 45, shownA in Figures 3 and 4, having spaced shafts 46 extending longitudinally there through, and each shaft is provided with a sprocket or pulley 41 about which a chain or belt 48 is trained in order. to rotate the shafts in unison. The shafts 45 are rotatably mounted in suitable bearings 50, and one of the shafts extends through the wall of the receptacle and has a manipulating lever 5i secured thereto. Cams 52 of the radiator cores and theterminal portions of the tubular cells which have had sumcient metal deposited'thereon in the previous electrolytic operation are masked out by theparamn coating, so that no additional metal is deposited on the paraffin coating, but additional metal is deposited on the intermediate portions of the tubes.' and this process is continued until the requisite quantity has been deposited on the intermediate portions of the tubesand all remote portions of the radiator cores. While two elecare secured at spaced intervals along each shaft 46, and these cams engage the lower surface of a grating or platform 53 which is mounted for vertical sliding movement in the tank or receptacle 45. Y 4

After the radiator cores or matrices have been subjected tothe electrolytic'bath for a period of time, in which the requisite quantity of metal is electrolytically deposited on the exposed portion of each matrix or core, the cores are then removed from the electrolyte and washed preparatory to their removal to the dipping or masking tank 45, shown in Figures 3 and 4. Afterl the matrices or cores 24 have been removed fron: the electrolytic bath and cleaned, any convenient number of them are then placed on the platform 53 with their tubular lcells 21 positioned upright.` The manipulating lever 5l is then roo tated, thereby rotating the cams 52 to lower the horizontal platform r53 until the lower terminals of the tubular cells 21 have been projected sufficiently far into the hot paraffin bath to coat the portion of the matrix which has sumclent metal deposited thereon. After the terminals of the cellular tubes 21 have been coated at the trolytic operations are sufficient in most instances, -it is, oi' course, to be understood that this operation may be repeated until the requisite quantity of material has been deposited on all portions of the radiator cores or matrices.

Any suitable means may be employed for heating they paramn in the tank 45, and, inasmuch as such heating means is common and well understood by those skilled in the art, it has not been illustrated in the application. Figure 9 depicts the condition of the radiator core or matrix after the requisite quantity of material has been electrolytically deposited thereon. If', for any reason, it should, be desirable to have a greater quantity of material deposited at the intermediate portion of each tube, this could be readily done by repeating the electrolytic process after the superficial or exposed portions of the matrix has been properly masked by dipping it in the parailin bath or other suitable masking fluid. Inasmuch as the cams 52 raise and lower the grating or platform 53 any predetermined dis# tance and maintains it in horizontal position, it

is manifest thaireach radiator matrix 24 may be dipped into the bath P a predetermined distance to accurately cover or mask the portion of the radiator which has received the requisite quantity of metal, thusleaving lthe remaining portion on which only a scanty supply of metal has been deposited free for subsequent electrolytic deposition. y

After the requisite quantity of metal has been uniformly electrolytically deposited on each matrix or core, the metal covered-matrix is then placed in an oven or otherwise heated until the temperature is raised above thefusing point of the fusible matrix or core, thereby melting the core but leaving the electrolytically deposited seamless shell intact. The molten matrix metal is drained from the shell, thus leaving a structure of the desired configuration with a hollow tank formed at its upper portion and a similar lower side of the submerged radiator cores 24 the cores are reversed on-the platform Staand the operation is repeated so that the portion of each radiator at its opposed side which has sufficient metal deposited thereon receives a coating or film of paraffin, which deposit or illm is best' indicated at F in Figure 8. In this f lgure the upper portions of the tubes have received their parailln bath, and their lower portions are being dipped in the bath a sufficient depth to masking processes, it is manifest that any degree oi. strength may be secured` according to the quantity or thickness of metal deposited. It is mask the portion of each tube which has had sufficient metal deposited thereon.v After the radiator cores have been dipped in the hot parailln to -receive a masking or film coating on their portions which have insuflicient metal thereon, these coresare again positioned in the electrolytic bath and the electrolytic process repeated. During this process the outer surface preferred, however, that these portions ofthe radiator be supplied with reinforcing members, and, to this end, a short nipple or tube 55, as shown in Figure 10, is cast or otherwise secured to the matrix, and this nipple is provided with an annular flange 5'6 winch s preferably embedded in the matrix, although it is to be understood that the flange may be secured to the outer present relatively great strength.

portion of the matrix if preferred. The matrix is then subjected to the hereinbefore described electrolytic process until a sufficient quantity of metal is deposited on the matrix and also on the nipple 55 andfits flange 56. After the matrix has been melted and removed from the electrolytically deposited metal, the nipple, 55 which is formed of copper, steel or other metal of high fusing point, remains as an integral part of the radiator shell and serves as a reinforcement for this portion.

The same method may be also employed to secure any reinforcing plate, securing pad or securing member to the radiator shell, and, in FigureA l1, there is depicted a method in which the reinforcing ear 23 is formed by casting or otherwise securing an angular plate 51 of relatively high fusing point to the matrix 24, and then electrolytically depositing the requisite quantity of metal thereover. After the fusible matrix has been removed from the electrolytically deposited radiator shell, the angular plate 51 remains as an integral part ofthe shell to serve as a reinforcement therefor. The body of the angular plate 51, in the form of the invention depicted in Figure 1l, is secured to the outer surface of the formed radiator matrixor core 24 so that the electrolytically deposited metal forms an offset portion. However, if preferred, the body of the angular plate 51 may belet into the matrix so that its outer face .is flush with the outer surface of the matrix 24, as depicted in Figure l2. While the plate 51 in the present instance has been shown as of angular formation,A it is, of course,to be understood that a reinforcing plate of any\ configuration may be secured to any selected portion of the radiator shell and formed integrally therewith by simply electrolytically depositing the requisite quantity of metal thereon. By this arrangement, securing or reinforcing pads or members may be placed at any desired portion of the radiator shell without affecting the process of electrolytically depositing the metal on the matrix.

From the foregoing it is seen that this'process enables the operator to control the quantity of metal electrolytically deposited on any portion g of the radiator. The remote or inaccessible portions of the radiator, which heretofore received only an insufficient quantity of metal, may be built up to any required thickness, and, if necessary or desired, the rempte or inaccessible portion will `,be deposited on the remaining portions ofY the tube so that the junctures between the tube terminals and the radiator front and back may What I claim as new and useful is): I l l. 'Ihe method of producing hollow radiator bodies having a plurality of tubes, which consists 4in forming a fusible core having tubular apertures extending therethrough, electrolytically depositing metal of higher fusing point than the core on the core, immersing opposed sides of the core to a predetermined depth in a bath of liquid masking material which liquees at a temperature lower than the melting point of the fusible core so that the masking material adheres to and covers the portions of the core and its tubular apertures on which suiiicient metal has been deposited, leaving the remote or intermediate portions of the tubular apertures on which an insufficient quantity of metal has been deposited free of the masking material, electrolytically .depositing additional metal on the unmasked portions of the radiator core until sufficient metal has been deposited on these portions, and raising the temperature of the core, masking material and deposited metal higher than the melting point of the fusible core to thereby melt the core and masking` material from the deposited metal.

s 2. The method of producing hollow radiator bodies having a plurality of tubes, which consists in forming a fusible core lhaving tubular apertures extending therethrough, electrolytically depositing metal of higher fusing point than the core on the core, immersing opposed sides of the core to a predetermined depth in a bath of llqud masking material which liqueiies -at a temperature lower than the melting point of the fusible core so that the masking material adheres to and covers the portions of the core and its tubular apertures on which suiiicient metal has been deposited, leaving the remote or intermediate portions of the tubular apertures on which an insuiilcient quantity of metal has been deposited free of the masking material, electrolytically depositing additional metal on the unmasked portions of the radiator core until sumoient metal has been electrolytically deposited on these portions, repeating these operations until predetermined quantities of metal have been electrolytically deposited on selected portions of the radiator, and raising the temperature of the core, masking material `and deposited metal higher than the melting point of the fusible core to thereby melt the core and4 masking material from the deposited metal. e y

3. The method ofv producing hollow radiator bodies having a plurality of tubes, which consists in forming a fusible core having tubular apertures extending therethrough, electrolyti cally depositing metal of higher fusing point than the core on the core, supporting the radiator core4 on a support which is movable vertically in a bath of liquid masking material which liquefies at a temperature lower than the melting point of the fusible core to thereby lower the core into the liquid masking material to a depth suflicient to cover the portions of the core and its tubular apertures on which suilicient metal has been electrolytically deposited, leaving the remote or intermediate portions of the tubular apertures on which an insufficient quantity of metal has been deposited free of the masking fluid, and raising the temperature of the core, masking material and deposited metal higher than the melting point of the fusible core to thereby melt the core and masking material from the deposited metal.

HERBERT 0. EWING. 

